Sheet metal split-bolt connector



June y27, 1939. a. nl BNE-R Er AL saam' METAL sPLIr'oL'r couuzcxfon Filed spt. 1o, 1937 2 meh-sheet 1 FIG.2

FIGA' FIG. I3

FIG. l2

. INVENTQRS lRN DIBNER u .JULIAN RoGoFF June 27, 1939. B. piBN'V-ER er A.. 2,164,006

snaar METAL SPLIT-nom' coml'scron Filed sept. 1o, 1957 2 shuts-sheet l2 F|G.|7 A Flew Plazo INVENTORS 'RN DlBNiR JULIAN RoGoFF @my ATTORNEY y Paten-ted June 27, l1939 2,164,006 SHEET METAL SPLIT-BOLT CONNECTOR Bern Dibner, Peekskill, and Julian Rogoif, New York, N. Y., assignors to Burndy Engineering Co., Inc., a corporation of New York Application September 10, 1937, Serial No. 163,186

5 Claims.

Our invention relates to split-bolt connectors for electric cables and more particularly to splitbolt connectors made of sheet metal.

The split-bolt type of electrical connector consists of a U-bolt with legs threaded on the outside only and a slot between the legs; a nut which screws onto the legs; and a follower which rides on the nut and in the slot between the U-bolt legs. In order to get a proper connection with this type of connector, it is essential that high pressures be exerted in clamping the conductors together.

This device is widely used throughout the electrical industry for making electrical connections and more especially by the public utility companies for making service connections.` The users of this type of connector, because of the large quantities in which they vare purchased, have demanded a less expensive product than can be manufactured by conventional methods. On the other hand, the demand for improved electrical and mechanical properties has been pronounced.

In the past the split-bolts of service connectors were manufactured as screw machine products or as forgings. The screw machine product was the first type available. By this method the split-bolt was manufactured from a free cutting rod in a` screw machine. After the rod was threaded and cut to length the threaded stud was then placed in a milling machine and slotted and additional operations were performed to remove burrs and sharp edges` Naturally, this process `involved several set-ups in different machines as well as waste of considerable metal. Inv addition the free cutting rod of which the split-bolts were made, had to be drawn of alloys which could be readily cut and could not be fabricated of the high strength alloyswhich are very tough and difficult to cut on a screw machine.

The forged split bolt was introduced in an effort to increase the strength of the connector and at the same time decrease the cost. By forging, it was possible to eliminate the waste of material which resulted from cutting the slot in the threaded stud. In addition, the alloys of which the split-bolt could be forged, Where the tough high strength alloys which were diicult to cut. This resulted in a connector of high strength and reduced cost.

In spite of the improvement effected by the introduction of the forging process, demand continued for a connector of still greater strength l and lower price. In common with screw machine manufacture, the forging process had the disadvantage that several operations 'were performed and each operation meant a new set-up and handling of the Isplit-bolt. Thus, although the forged split-bolt could be manufactured at a lower `price than the'screw machine split-bolt, 5 and was a stronger .product, there still was a demand for a less expensive and still stronger device.

In order to make a split-bolt of maximum strength by the most economical method, our invention was devised whereby the split-bolt is 10 manufactured of sheet metal. A sheet metal split-bolt may be manufactured on high speed production machinery capable of performing several operations automatically in rapid succession and with no handling by an operator bel5 tween operations. Sheet metal strip may be fed into the machine and successive operations will blank, clip, form andbend the split-bolt. Even the threading may be accomplished automatically by a finger which carries the unthreaded split- 20 bolt to a threading mechanism.

Alternatively the sheet metal may be cupped, stamped, threaded, and sheared, all automatically. This method is not so desirable as the previous method because of the waste material 25 which must be sheared away in order to form the slot.

Therefore, one object of our invention is to provide a connector made of sheet metal adaptable to mass production methods and wherein 30 waste of material is held to a minimum.

Sheet metal is especially desirable for the fabrication of split-bolts. It can `be rolled and drawn from high strength alloys and may be cold worked to a pointwhere the material attains 35 its maximum hardness. From this viewpoint it is superior to both rod and forgings; the first because the rod must be free-cutting; the second because the forging must originally befabricated from a soft slug and although the metal is 40 hardened by the succeeding cold working operations, it cannot attain a degree of hardness as great or as homogeneous as can be attained with sheet metal.

Accordingly, another object of our invention 45 is to provide a connector of as high strength and hardness as can be obtained from sheet metal.

An extremely important advantage of the splitbolt service connector over types previously used, is that it may be salvaged and reused. However, this calls for a connector which will not be readily distorted. Long before the connector` will fail, the legs of the split-bolt will tend to twist with the result that when the connector is used and thcn removed, the split-bolt will be so distorted as to prevent reuse.

Another object, therefore, of our invention is to provide a connector which will not distort at high values of wrench-torque and will be reusable after being installed.

In order to prevent the legs of the split-bolt from moving in relation to each other, we provide a segmental pocket in the inwardly facing surfaces of the threaded legs. The follower which rides in the slot in the split-bolt is formed with projections which closely fit the segmental pockets. Thus, in addition to providing support to the legs of the split-bolt when pressure is applied by the nut, the follower also prevents the legs of the split-bolt from moving in relation to each other and thereby raises the value of wrench torque necessary to cause distortion of the connector.

Consequently, a still further object is to provide means for reinforcing the legs of the sheet metal split-bolt to prevent distortion or torsional failure.

Another fault, common to the split-bolt connectors now in use, is the "galling of the metal in the threads where the nut rides on the splitbolt. This galling consists of a small particle of metal being worm from the split-bolt by the friction of the revolving nut. This metal particle then travels with the nut and continues to roll up metal from the split-bolt threads, somewhat as a snowball keeps getting larger as it rolls through the snow. This ball of metal finally gets so large that it will jam the nut and make proper tightening of the connector difficult. In addition, it will make it practically impossible to remove the nut from the split-bolt when the Joint is to be disconnected and the connector reused.

Another object is to provide al split-bolt connector in which galllng will be eliminated.

In order to avoid galling it is desirable to use a hard alloy which will not wear or seize readily. Greater hardness can be obtained in sheet metal than in either a forging or screw machine products. It is, therefore, evident that the sheet metal connector will be reusable at higher values of wrench-torque from this aspect.

In order to obtain a fiat sided head which will provide a -irm base for pliers or wrench, the head of the split-bolt is flattened and elongated. This is accomplished by proper formingrof the sheet metal blank.

Accordingly, another object of our invention is to provide a connector which can be readily gripped by pliers or Wrench in order that it c be tightened securely.

In addition to demanding increased strength and lower cost a considerable number of public utility companies require split-bolt connectors equipped with nut retainers. Such connectors, as made in the past, have usually required several expensive operations to be performed on the splitbolt. We taken advantage of the segmental pocket formed in the leg of our split-bolt to provide space in which a nut retainer can ride and we thus eliminate all except Va. single simple assembly operation.

Hence, a still further object is to provide a v2,164,0oe

the split-bolt supports the legs and prevents failure of the connector by collapse of the legs. In the ordinary split-bolt when the pressure is relieved by unscrewing the nut, the legs of the splitbolt will remain squeezed in tight frictional relationship with the follower, and the nut-follower assembly will be difilcult to remove from, or reassemble to, the split-bolt. Because of the springiness which it is possible to obtain with sheet metal, the legs of the split-bolt so made, will recover their original position when pressure is relieved.

Another object therefore, is to obtain a resiliency in the split-bolt connector, to permit stressed parts to spring back to their original position when the stresses are removed.

Still another advantage of sheet metal is the tolerances to which a device made of this material may be held. Inasmuch as the clearances between follower and split-bolt, and between the split-bolt and nut, must be kept small, this is a very important advantage. Il' the clearances mentioned above are excessive the split-bolt legs will collapse on the follower to such an extent that the nut may ride up and over the tops of the threads on the split-bolt and cause the joint to fail.

Another object therefore, it to provide a splitbolt connector having close tolerances between the legs of the bolt, the follower, and the nut, to

avoid thread skipping.

We accomplish these and other objects of our invention by the sheet metal split-bolt connector described in the following specification and illustrated in the accompanying drawings in which:

Fig. 1 is a plan view of the sheet metal blank into which the split-bolt is formed,

Fig. 2 is a side view of the same.

Fig. 3 is a plan view of the blank after an initial forming operation.

Fig. 4 is a side view of the same.

Fig. 5 is a front view of the completely formed and threaded split-bolt.

Fig. 6 is a side view of the same.

Fig. 7 is a bottom view.

Fig. 8 is a side view of a sheet metal cap from which a modified form of split-bolt is made.

Fig. 9 is a bottom view of the same.

Fig, 10 is a front view of the partially finished modification.

Fig. 11 is a side view of the same.

Fig. 12 is aA front view after the threading operation.

Fig. 13 is a front view showing the completed split-bolt.

Fig. 14 is a front view of the assembled connector.

Fig. 15 is a side view of the same.

Fig. 16 is a top view of the assembled connector with a novel forni of reinforcing follower.

Fig. 17 is a sectional view of the split-bolt with a novel nut retainer.

Fig. 18 is a top sectional view illustrating means for holding the nut retainer.

Fig. 19 is a side view of the connector with th novel nut retainer.

Fig. 20 is a front view of the connector, with nut held in extended position by our novel retainer.

Fig. 2l is a perspective view of the reinforcing follower made from sheet metal.

Fig. 22 is a top view of a reinforcing follower with a channel for the nut retainer.

Referring more particularly to Figs. 1 and 2 of the drawings, reference numeral I0 designates tehbe properly centered, the external fiat side.

walls I'permittinga wrench to be applied thereto. IThreads I6 are thereafter formed on the legs for threaded engagement with a nut. i

The splitbolt may alternatively be drawn from` sheet metal into. a cap-shaped member -I'I, as shown in Figs. 8 and 9, the top of which'is subsequently formed into a head section I8, having fiat sides I9, for permitting a wrench to be appliedanda cylindrical body` section 20, as shown in Figs. 10 and 1l. The body section 20 is thereafter threaded as at 2I, and slotted as at- 22,;to forma split-bolt, as shown in Figs. 12and 13.

In Figs. 14, 15 and 16. we have shown our. 'preferred sheet metal split-bolt, 23 assembled about a pair of conductors 24. A follower 25,of* unusualconstruction, hereinafter described, and

a nut 26` completes the assembly.. 1

The` follower 25 is shown as solidly made forging, although, as may be seen in Fig. 21, it 4may ances, obtainable'by the use of sheet metal makes i end of leg 34 tends to move.

be madel of sheet metal. cable supporting section 21, and two nut retaining wings 28 .and 29, respectively. As illustrated, the nut mayA bev rotated about the legs `of the split-bolt ywithout rotating the follower, which rides up and down the legs of the split-bolt as propelled by the nut and the engaging wings 28 and 29 which prevent the nutfrom being separated therefrom. The retaining wing 29, may

be made as shown, by severing a section of the upper surface 30,' of the follower 25, and bending it over to engage the nut surface 3|.

We have reinforced the hollow legs -off the split-bolt by providing semi-cylindrical ridges 32 on the inner Vsides of the follower 25 which t snugly within the hollow legs of the splitbolt and ride the inside'surfaces as the nut is rotated.

Thus, as the nut is rotated in the direction indicated by the arrow A in Fig. 16, leg 33 receives a torsional stress tending to move its free end in the direction of arrow B.v Similarly, arrow C, indicates the direction towards which the free By providing the reinforcing ridges 32 on the inner sides of the follower 25, the free ends ofthe legs 33 and 34 are kept in their proper position and reinforced against movement. Close tolerpossible'a relatively small space .for movement,

thus resulting in less distortion with an increased factor of reusability..

In Fig. 17 the upper end of the leg 35 of the split-bolt .36, is stamped with projections 3Il and 38. A vwire formed nut retainer 39, with stops A4I) and-4I, engage the upper surface 42 of the nut 43,v and the bent over projections 31 and 38, respectively, to prevent separation ofA the nut from the retainer, or the retainer from the splitbolt'. r y

This type of retainer is made possible -by the hollows 44 formed within thecylindrically formed legs 35 of the split-bolt connector 36.

In Fig. 21A a sheet metal follower `45 is illustrated which may be substituted for the type illustrated in Fig. 16. This is made by folding over the sheet metal into a-box-like construction, with wings 46 and .41 for retaining the nut It is. formed with a therein, and sides 48, formed' into ridges 49, for. reinforcing the hollow legs of the split-bolt. The wing 46 may becurved so as to engage the curved cable, .supported within the split-bolt.

In Fig. 22, the reinforcing follower 50 is provided with an inwardly formed channel 5I to provide space for the nut retainer 39 and bent over' projections 31 and 38,. Thus, the legs of the split-boltmay be reinforced and applicants novel rtype of nut retainer all incorporated in the sheetV metal split-bolt connector. Obviously, the follower 50 may be solidly constructed as shown in Fig..16,-orof sheet metal as shown in Fig. 21.

We have in the foregoing devices provided a connector made of resilient sheet metal adapted for manufacture by mass production methods,

wherein waste of material is held to a minimum.

. We use sheet metal, a material in which maximum hardness may be obtained with the greatest homogenlety-and free fromI defects'aptto cause fractures when over stressed.

By making the legs of the split bolt of sheet metal, we obtain segmental pockets, which fwe reinforce and interlock by our improved follower,

thereby, strengthening the legs and preventing i movement and subsequent distortion.

Cialling is prevented by the use of extremely hardalloys obtainable in sheet metali form, which will not wear or seize readily. In addition, sheet'v metal made from. properly selected alloys will enable us to obtain a resiliency, necessary for restoring the legs'f the spit bolt to their original position, as well as an accuracy in the stamping process for obtaining close tolerances necessary for close fitting parts.

By utilizing the segmental pocket in the leg, we provide a novel nut retainer which' is simple to make and assemble.

We have -thus described our invention, but wedesire it understood that it is not confined to the particular forms or usesshown and described,

.thesame'being merely illustrative, and that the invention may be carried out in other ways fwithout departing from the spirit of our invention and, therefore, we claim broadly the right to employ all equivalent instrumentallties coming with-g' in the `scope of the appended claims, and by means of which, objects of our invention are attained and newl results accomplished, as it is Y obvious that the particular embodimentsherein shown and described are only some of the" many, that can be employed to attain these ob jects and accomplish these results.

Whatwe claim and desire to secure by Letters g Patent, is a follows:

lindrically formed with external and internal concentrically arranged surfaces, the external surfacesof which'are threaded for engagement with a nut.

2. A split-bolt connector having a split-bolt,`

a pressure bar, a nut, and a nut retainer, said split-bolt formed of a singlesheet of metal and comprising a centrally located head, and a pair of extending legs, integral with said head and bent at right angles thereto, said legs cylindrically formed with external and internal concentrically arranged surfaces, the external surfaces of which are threaded for engagement with said nut; said nut retainer comprising an elongated metallic means having a head at one end for slidable engagement between said nut and pressure bar, and another head at the remaining end for engagement with only one of the legs of said split-bolt, said elongated metallic means Slidably attached t and lying Within the enm- 3. A split-bolt connector having a split-bolt,4

a pressure bar, a nut, and a nut retainer, said split-bolt formed of a single sheet of metal and comprising a centrally located head, and a pair of extending legs, integral with said head and bent at right angles thereto, said legs cylindrically formed with external and internal concentrically arranged surfaces, the external surfaces of which are threaded for engagement with said nut, one of said legs provided with a bent over projection at its free end for slidable engagement with said nut retainer; said nut retainer comprising an elongated metallic means having a head at one end for slidable engagement between said nut and pressure bar, and another head at the remaining end for engagement with s'aid bent over projection; said elongated metallic means slid-V ably attached to and lying within the engaging leg along its internal cylindricaliy formed surface.

4. A split-bolt connector having a split-bolt, a

nut, and a follower, said split-bolt formed of a' single sheet of metal and comprising a centrally located head, and a pair of extending legs, integral with said headand bent at right angles thereto, said'legs cyiindrically formed with external and internal concentrically arranged surfaces, the external surfaces of which are threaded for engagement with said nut; said follower com prising a main body section having an upper and lower surface and two sides: a pair of wing sections, extending from lthe upper and lower surfaces of said follower, for engagement with the upper and lowersurfaces of said nut, allowing said nut to rotate `"freely therein, said two sides arcuately formed to nt snugly within the internal cylindrically formed surfaces of said legs whereby said follower may ride said surfaces when said follower is propelled along said legs by said nut.

5. A split-boltconnector having a splitbolt. a nut, and follower; said split-bolt formed of a single sheet of metal and comprising a centrally located head, and a pair of extending legs; integral with said head and bent at right angles thereto, said legs cylindxically formed with external and internal concentrically arranged surfaces, the external surfaces of which are threaded for engagement with said nut; said follower formed of sheet metal and comprising a main body section having an upper and lower surface, and two sides, a pair of wing sections made of sheet metal extending from the upper and lower surfaces of said follower, and adapted to engage the upper and lower surfaces of said nut, allowing said nut to rotate freely therein, said two sides made of sheet metal and arcuately formed to fit snugly within the internal cylindrically formed surfaces of said legs whereby said follower may ride said surfaces when said follower is propelled along said legs by said nut.

BERN DIBNER. JULIAN RDGOFF. 

